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304.8 mm) were machined from the bar stock. All specimens were carburized and heat treated
per Rolls-Royces process specification EPS200 to achieve a surface hardness of 62 Rc and a
depth of carburized layer of 0.05 in. (1.27 mm). Test specimens were subsequently machined
to final dimensions. At least 0.005 in. (0.13 mm) of material was ground from each gage section
to remove the decarburized layer before final processing.
Specimen Processing
LPB process parameters were developed for both specimen types to achieve nominally 0.030
in. (0.76 mm) of compression. Samples were processed on a CNC mill to allow positioning of
the LPB tool in a series of passes along the active gage region. LPB test specimens had an
additional 0.005 in. (0.13 mm) of material removed by grinding after the LPB processing to
correct specimen geometry after the quenching process. All SP was performed per Rolls
Royces process specification EPS12176G. Baseline specimens were left in the as ground
condition after the decarburized layer was ground off.
Residual Stress and Retained Austenite Measurements
X-ray diffraction residual stress measurements were performed using a sin2 technique
employing the diffraction of Cr K-alpha 1 radiation from the (211) planes of the BCC structure of
the 9310 gear steel. The diffraction peak angular positions at each of the psi tilts employed for
measurement were determined from the position of the K-alpha 1 diffraction peak separated
from the superimposed K-alpha doublet assuming a Pearson VII function diffraction peak profile
in the high back-reflection region. The diffracted intensity, peak breadth, and position of the Kalpha 1 diffraction peak were determined by fitting the Pearson VII function peak profile by least
squares regression after correction for the Lorentz polarization and absorption effects and for a
linearly sloping background intensity. 10,11,12,13 Where appropriate, material was removed
electrolytically for subsurface measurement in order to minimize possible alteration of the
subsurface residual stress distribution as a result of material removal. The residual stress
measurements were corrected for both the penetration of the radiation into the subsurface
stress gradient 14 and for stress relaxation caused by layer removal. 15 The volume percent
retained austenite was determined using the direct comparison method of Averbach and Cohen 16
in accordance with ASTM E975 and SAE SP-453.
Figure 2: Photographs Showing the Location of the 0.1 in. Long x 0.010 in. Deep EDM Notch on
the Top Face of the Specimen. The Notch is Shown on an Untested Specimen on the Left and
on the Fracture Face of a Tested Specimen on the Right.
Stability of Residual Stress
The effect of cyclic loading on the stability of residual stresses in LPB treated specimens was
investigated. This was accomplished by comparing residual stress distributions in LPB treated
specimens both before and after HCF testing was performed.
The effect of mechanical overload on the stability of residual stresses was investigated. To
accomplish this two specimens were prepared by low stress grinding (LSG). One specimen was
shot peened on both surfaces and the second specimen was LPB processed on both surfaces.
The specimens were deformed in 3-point bending to a predetermined maximum plastic strain
level at mid-point, creating a plastic strain gradient as a function of distance from the mid-point.
Therefore, a single specimen could be used to test the effect of tensile (bottom surface) and
compressive (top surface) overload. Surface residual stresses were measured by x-ray
diffraction (XRD) methods as a function of distance along the length of the specimens. Each
sample was displaced a total of 0.8 in. (20.3 mm) at mid-length (center) in the bending fixture.
The maximum plastic deformation at the sample center was approximately 1.3% for the shot
peen sample and approximately 1.4% for the LPB processed sample. The plastic deformation
was of low magnitude for both samples beyond 3 in. (76.2 mm) from the center. XRD residual
stress measurements were made at the surface, in the longitudinal direction, on both the
compressive and tensile applied stress sides. Measurements were made from the center of the
bend out to a distance where the plasticity from bending was at or near zero.
The effect of thermal relaxation on the stability of residual stresses was also investigated. To
accomplish this two specimens were prepared by low stress grinding (LSG). One specimen was
SP on both surfaces and the remaining specimen was LPB treated on both surfaces. The effect
of thermal exposure was studied by exposing each specimen to temperatures ranging from
156C to 192C (312.8 377.6F) for 24 hours in a linear tube furnace. Surface residual
stresses were measured by x-ray diffraction methods as a function of position / temperature
along the length of the specimens after thermal exposure.
Surface Roughness
The surface roughness of the LPB treated thick section specimens after processing was
compared to the Baseline (ground) and SP treated HCF specimens. Surface roughness value,
Ra, was an averaged of 3 passes over 0.150 in. (3.8 mm) transverse to the specimen axis, and
over 0.5 in. (12.7 mm) longitudinal with the specimen.
RESULTS
Residual Stresses
Figure 3 contains a plot of the residual stress distribution for the baseline (ground), SP, and LPB
processed conditions. The baseline condition shows a compressive layer at a nominal stress
level of approximately 75 ksi. In the SP condition, the surface compression of 140 ksi
changes as a function of depth and a maximum compression of 220 ksi is seen at a depth of
approximately 0.002 in. (0.05 mm). The stress then gradually decreases to approximately 50
ksi at depths of 0.010 in. (0.25 mm) and beyond. LPB processed specimens shows a surface
compression of 140 ksi, which gradually increases to approximately 270 ksi at a depth of
0.005 in. (0.13 mm), and further gradually decreases to near zero at a depth of 0.030 in. (.76
mm). The higher magnitude and depth of compression provided by LPB processing when
compared to SP provides greater fatigue strength and helps mitigate the effect of contact
fretting damage fatigue performance. The benefit on fatigue performance that LPB processing
provides is discussed in detail in the experimental results section for HCF testing.
LONGITUDINAL RESIDUAL STRESS DISTRIBUTION
-3
50
Depth (x 10 mm)
0 100 200 300 400 500 600 700 800 900100011001200
-50
-400
-100
-800
-150
As-Ground
Shot Peened
LPB
-200
-250
-300
-1200
-1600
-2000
0
10
20
30
-3
Depth (x 10 in.)
40
50
Figure 3: Plot of Residual Stress vs. Depth in the As-Ground, Shot Peened and LPB Treated
Carburized and Heat Treated 9310 Gear Steel Specimens.
Retained Austenite
The mean volume percent retained austenite is presented in Figure 4. The surface austenite
content is approximately 17%, which remains the same as a function of depth for the baseline
specimen. For the SP specimen the retained austenite reduces to approximately 9% at a depth of
0.001 in. (0.03 mm) and then gradually increases to approximately 15% at depths beyond 0.005 in.
(0.13 mm). In the LPB treated specimen the retained austenite decreases to approximately 8% to a
depth of 0.005 in. (0.13 mm) and then gradually increases to approximately 12% at depths beyond
0.020 in. (0.51 mm). The implications on fatigue performance due to a change in volume percent
austenite where not studied in this investigation.
30
9310 Carburized and Heat Treated
Retained Austenite Vs Depth
20
10
Baseline
SP
LPB
0
0.00
0.01
0.02
0.03
0.04
0.05
Depth, in.
Figure 4: Plot of % Retained Austenite vs Depth for Baseline, Shot Peened and LPB Treated
Specimens.
1500
250
a,b
a
a
200
1200
150
900
100
600
300
0.010 in.
EDM Notched
Smooth
Baseline
Shot Peened
LPB
0
3
10
10
Notes:
a - Crack initiated from a corner
b - Subsurface initiation
5
10
50
1800
10
10
CYCLES TO FAILURE
Baseline
Shot Peened
LPB Treated
150
25
Smooth
50
200
Smooth
75
Smooth
100
250
Smax @ 10 Cycles,
(% of Baseline Smooth Condition)
125
100
50
0
Figure 6: HCF Performance of Untreated, Shot Peened, and LPB Treated Posts With and
Without a 0.010 in. Deep EDM Notch to Simulate Contact (Pitting) Damage on the Gear Tooth.
HCF test results are also presented graphically in the form of a bar chart in Figure 6. The fatigue
strength of the baseline smooth parts is defined to be 100%. As shown here, the baseline
specimens with the EDM notch condition have a fatigue strength loss of over 70% of that of the
baseline smooth condition. Similarly, while the SP smooth condition shows a 10% improvement
over the baseline smooth, the introduction of an EDM notch still leads to over 50% reduction in
fatigue strength. LPB treated smooth specimens showed a 20% improvement over the baseline
smooth condition and a 10% improvement over the shot peened smooth condition. With the
introduction of an EDM notch the fatigue strength dropped only by approximately 15%
compared to the baseline smooth condition.
The increase in fatigue performance that LPB processing provides can lower maintenance cost
for drive train components. This would be achieved by lengthening the time interval between
inspections. LPB processing can provide a higher allowable load on gear teeth for a given
dimensional or weight requirement.
Following fatigue testing, each specimen was examined optically to identify the location of the
fatigue origins. Shown below in Figure 7 are typical fracture surfaces of baseline (9a), SP (9b),
LPB processed (9c), and notched specimens (9d). All notched specimens failures initiated from
the notch so only one process condition is shown, LPB processed.
50
Depth (x 10 mm)
0 100 200 300 400 500 600 700 800 900100011001200
-50
-400
-100
-800
-150
LPB + Ground
LPB + Ground
+ Fatigue Tested
Smax = 245 ksi
Nf = 129,406 Cycles
-200
-250
-300
-1200
-1600
-2000
0
10
20
30
-3
Depth (x 10 in.)
40
50
Figure 8: Residual Stresses in LPB Treated Specimens Before and After Fatigue Testing.
Mechanical Overload Relaxation
A comparison of surface residual stresses between the LPB treated and SP samples are shown
in Figure 9a. A corresponding residual stress distribution at a depth of 0.005 in. (0.13 mm) for
both LPB treated and SP samples are shown in Figure 9b. Results are shown on a semilogarithmic plot in these figures to expand the scale at the relatively low plastic strain levels.
As shown in Figure 9a, on the surface, both LPB and SP resulted in similar residual stress
distributions. Similar variations in residual stresses after plastic deformation were observed for
the two surface treatments on both the tensile and compressive sides. For both treatments, the
residual stresses were not seen to relax for plastic deformation up to approximately 0.4% and
some relaxation of residual stresses were observed for plastic strain above 0.4%. The tensile
overload appears to result in greater relaxation of residual stresses compared to the
compressive overload.
500
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Lambda Technologies
1524-15265
April 14, 2010
-50
-500
-100
-1000
-150
-200
-250
-1500
Shot Peened (
LPB Processed (
Tensile Side
Tensile Side
Compressive Side)
Compressive Side)
-2000
-300
0.01
0.1
Percent Strain (%)
Figure 9a: Comparison of Surface Residual Stress as a Function of Bulk Plastic Deformation in
Carburized and Heat Treated 9310 Gear Steel 3-Point Bend Beams.
At a depth of 0.005 in. (0.13 mm), the LPB processed specimen showed a higher magnitude of
compression, (250 to 280 ksi), while the SP specimen showed a lower magnitude of
compression (110 to 150 ksi). Although both specimens showed relaxation of residual
stresses at plastic deformation greater than 0.4%, due to the initial high magnitude of
compression for the LPB processed specimen, it retained a substantial amount of compressive
residual stresses, even at plastic strain levels greater than 1%. In contrast, the SP specimen
showed nearly complete stress relaxation and even transition of the residual stresses from
compression to tension at high plastic strain.
500
50
Lambda Technologies
1524-15265
April 14, 2010
-50
Shot Peened (
LPB Processed (
Tensile Side
Tensile Side
Compressive Side)
Compressive Side)
-500
-100
-1000
-150
-200
-1500
-250
-2000
-300
0.01
0.1
Percent Strain (%)
Figure 9b: Comparison of Residual Stress as a Function of Bulk Plastic Deformation at a Depth
of 0.005 in. in Carburized and Heat Treated 9310 Gear Steel 3-Point Bend Beams.
Thermal Relaxation
The results shown in Figure 10 show the effect of thermal exposure on the relaxation of surface
residual stresses from SP and LPB processing. Residual stress measurements were made on
the thermally exposed surfaces and at a depth of 0.005 in. (0.13 mm) in both SP and LPB
treated specimens.
50
-50
Surface (LPB)
Surface (Shot Peen)
-500
-100
-1000
-150
-200
-1500
-250
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April 7, 2010
-300
150
160
170
180
Temperature (C)
190
-2000
200
Figure 10: Comparison of Shot Peened and LPBed Residual Stress for 9310 Steel Carburized
Steel Exposed at Temperatures of 156C to 192C C for 24 Hrs.
As seen in this figure, very little relaxation of residual stresses result from thermal exposure for
both the shot peened and the LPB treated specimens. As observed before, the near surface
compression for both surface treatments are similar, while at the 0.005 in. (0.13 mm) depth, the
LPB treated specimens show higher magnitude of compression. This is a result of the depth of
compression introduced by LPB.
Surface Roughness
The results of the surface roughness measurements for each process are shown in Figure 11 in
the form of a bar chart. The surface roughness is lowest for the LPB process, indicating a
smoother surface as compared to the ground or shot peened surfaces. Smother surfaces lead
to less friction between gear teeth and ultimately greater contact fatigue life. Lower friction also
reduces noise and oil / material temperature.
9310 Carburized and Hardened Gear Steel
Ra Surface Roughness
30
20
Transverse
LPB
Shot Peened
Baseline
LPB
10
Shot Peened
15
Baseline
25
Longitudinal
Figure 11: Bar Chart Showing the Comparison of the Surface Roughness of Baseline (Ground)
and Shot Peened Specimens versus LPB Treated Specimens.
CONCLUSIONS
A comprehensive study was undertaken to demonstrate the benefits of using LPB technology to
introduce controlled distribution of compressive residual stresses to improve fatigue
performance and damage tolerance in carburized and heat treated 9310 gear steels used in
rotorcraft gears. The following conclusions may be reached from this study:
LPB produces a much smoother surface, with a surface roughness of 5 10 in, while
the SP leads to a relatively rough surface with 25 in of Ra surface roughness.
In summary, the LPB treatment has been demonstrated to have improved the fatigue
performance over the standard shot peening treatment in carburized and heat treated 9310 gear
steels, and improve the resistance to simulated contact pitting damage. This demonstration
paves the way for developing applications of this technology for actual gears by appropriate
design of LPB tools and implementation of the designed residual stresses to improve the
performance of rotorcraft gears.
Acknowledgment
Funding from the Army SBIR program Topic No. A09-014, Contract No. W911W6-10-C-0005
(TPOC: Clay Ames, AATD) is gratefully acknowledged. The authors also wish to thank Steve
Hammond for the assistance provided by Rolls Royce, Indianapolis with the carburizing and
heat treatment of specimens, and for technical discussions.
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3
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5
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9
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11
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